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BHE000000001E01
Range of Topics
This manual contains procedures for performing all required service operations. The procedures are divided into
the following five basic operations:
Removal/Installation
Disassembly/Assembly
Replacement
Inspection
Adjustment
Simple operations which can be performed easily just by looking at the vehicle (i.e., removal/installation of parts,
jacking, vehicle lifting, cleaning of parts, and visual inspection) have been omitted.
Service Procedure
Inspection, adjustment
Inspection and adjustment procedures are divided into steps. Important points regarding the location and
contents of the procedures are explained in detail and shown in the illustrations.
Repair procedure
1. Most repair operations begin with an overview illustration. It identifies the components, shows how the parts fit
together, and describes visual part inspection. However, only removal/installation procedures that need to be
performed methodically have written instructions.
2. Expendable parts, tightening torques, and symbols for oil, grease, and sealant are shown in the overview
illustration. In addition, symbols indicating parts requiring the use of special service tools or equivalent are also
shown.
3. Procedure steps are numbered and the part that is the main point of that procedure is shown in the illustration
with the corresponding number. Occasionally, there are important points or additional information concerning a
procedure. Refer to this information when servicing the related part.
Symbols
There are eight symbols indicating oil, grease, fluids, sealant, and the use of SST or equivalent. These symbols
show application points or use of these materials during service.
Symbol
Meaning
Apply oil
Kind
Apply grease
Appropriate grease
Apply sealant
Appropriate sealant
Replace part
Appropriate tools
Advisory Messages
You will find several Warnings, Cautions, Notes, Specifications and Upper and Lower Limits in this manual.
Warning
A Warning indicates a situation in which serious injury or death could result if the warning is ignored.
Caution
A Caution indicates a situation in which damage to the vehicle or parts could result if the caution is ignored.
Note
A Note provides added information that will help you to complete a particular procedure.
Specification
The values indicate the allowable range when performing inspections or adjustments.
UNITS
BHE000000002E01
Electric current
A (ampere)
Electric power
W (watt)
V (volt)
mm (millimeter)
in (inch)
kPa (kilo pascal)
Number of
revolutions
Torque
Volume
ml (milliliter)
cc (cubic centimeter)
cu in (cubic inch)
fl oz (fluid ounce)
Weight
g (gram)
oz (ounce)
Rounding Off
Converted values are rounded off to the same number of places as the SI unit value. For example, if the SI unit
value is 17.2 and the value after conversion is 37.84, the converted value will be rounded off to 37.8.
The actual converted values for 2.7 kgf/cm2 are 264 kPa and 38.4 psi. In the first specification, 2.7 is used as an
upper limit, so the converted values are rounded down to 260 and 38. In the second specification, 2.7 is used as a
lower limit, so the converted values are rounded up to 270 and 39.
NEW STANDARDS
BHE000000003E02
Previous Standard
Abbreviation
Name
Remark
Name
AP
Accelerator Pedal
Accelerator Pedal
ACL
Air Cleaner
Air Cleaner
A/C
Air Conditioning
Air Conditioning
BARO
Barometric Pressure
Atmospheric Pressure
B+
Vb
Battery Voltage
Brake Switch
Stoplight Switch
Calibration Resistor
Corrected Resistance
CAC
Intercooler
CLS
Feedback System
CTP
Fully Closed
CPP
Idle Switch
CIS
Clutch Position
CS sensor
CSP sensor
CKP sensor
DLC
Diagnosis Connector
DTM
Test Mode
DTC
Service Code(s)
DI
Distributor Ignition
Spark Ignition
DLI
Distributorless Ignition
Direct Ignition
EI
Electronic Ignition
ECT
Water Thermo
EM
Engine Modification
Engine Modification
EVAP
Evaporative Emission
Evaporative Emission
EGR
Exhaust Gas
Recirculation
FC
Fan Control
Fan Control
FF
Flexible Fuel
Flexible Fuel
#6
#6
#1
#2
4GR
Fourth Gear
Overdrive
#3
FCV
#6
GEN
Generator
Alternator
GND
Ground
Ground/Earth
HO2S
Oxygen Sensor
IAC
IDM Relay
Injection Pump
FIP
Pulse Generator
IAT
KS
Knock Sensor
Knock Sensor
MIL
Malfunction Indicator
Light
MAP
Airflow Sensor
MFL
OBD
On-Board Diagnostic
Diagnosis/SelfDiagnosis
OL
Open Loop
Open Loop
OC
Catalytic Converter
O2S
Oxygen Sensor
Oxygen Sensor
PNP
Park/Neutral Position
Park/Neutral Range
Main Relay
PSP
PCM
ECU
PAIR
Pulsed injection
NE Sensor
#6
AIR
SAPV
Reed Valve
SFI
Shift Solenoid A
Shift Solenoid B
Shift Solenoid C
3GR
Third Gear
3rd Gear
TWC
Catalytic Converter
With heater
#6
#6
#6
#4
TB
Throttle Body
Throttle Body
TP sensor
Throttle Sensor
TCV
TCV
TCC
Lockup Position
TCM
ATF Thermosensor
TR
Inhibitor Position
TC
Turbocharger
Turbocharger
VSS
VR
Voltage Regulator
IC Regulator
VAF sensor
WUTWC
Catalytic Converter
WOT
Fully Open
#6
#5
FUNDAMENTAL PROCEDURES
BHE000000004E01
Disassembly
If the disassembly procedure is complex, requiring many parts to be disassembled, all parts should be marked in
a place that will not affect their performance or external appearance and identified so that reassembly can be
performed easily and efficiently.
Arrangement of Parts
All disassembled parts should be carefully arranged for
reassembly.
Cleaning of Parts
All parts to be reused should be carefully and thoroughly
cleaned in the appropriate method.
Warning
Using compressed air can cause dirt and other
particles to fly out causing injury to the eyes. Wear
protective eye wear whenever using compressed
air.
Reassembly
Standard values, such as torques and certain adjustments, must be strictly observed in the reassembly of all
parts.
Oil seals
Gaskets
O-rings
Lockwashers
Cotter pins
Nylon nuts
Depending on location:
Sealant and gaskets, or both, should be applied to
specified locations. When sealant is applied, parts
should be installed before sealant hardens to
prevent leakage.
Oil should be applied to the moving components
of parts.
Specified oil or grease should be applied at the
prescribed locations (such as oil seals) before
reassembly.
Adjustment
Use suitable gauges and testers when making adjustments.
Hose Clamps
When reinstalling, position the hose clamp in the original
location on the hose and squeeze the clamp lightly with
large pliers to ensure a good fit.
Torque Formulas
When using a torque wrench-SST or equivalent
combination, the written torque must be recalculated due
to the extra length that the SST or equivalent adds to the
torque wrench. Recalculate the torque by using the
following formulas. Choose the formula that applies to you.
Torque Unit
Formula
Nm
Nm [L/(L+A)]
kgfm
kgfm [L/(L+A)]
kgfcm
kgfcm [L/(L+A)]
ftlbf
ftlbf [L/(L+A)]
inlbf
inlbf [L/(L+A)]
A : The length of the SST past the torque wrench
drive.
L : The length of the torque wrench.
Vise
When using a vise, put protective plates in the jaws of the vise to prevent damage to parts.
ELECTRICAL SYSTEM
BHE000000006E01
Connectors
Disconnecting connectors
When disconnecting connector, grasp the
connectors, not the wires.
Locking connector
When locking connectors, listen for a click
indicating they are securely locked.
Inspection
When a tester is used to inspect for continuity or measuring voltage, insert the tester probe from the wiring
harness side.
Inspect the terminals of waterproof connectors from the connector side since they cannot be accessed from
the wiring harness side.
Caution
To prevent damage to the terminal, wrap a thin wire around the tester probe before inserting into terminal.
ABBREVIATIONS
BHE000000011E01
AT
Automatic Transmission
MT
Manual Transmission
13B-MSP
STANDARD POWER HIGH POWER
(mm {in})
0.04 {0.0016}
Maximum wear
(Vertical wear)
(mm {in})
0.10 {0.0039}
Maximum wear
(Convex oval)
(mm {in})
Maximum wear
(Oil seal stepped path wear)
0.01 {0.0004}
0.10 {0.0039}
(mm {in})
0.02 {0.0008}
ROTOR HOUSING
Maximum width difference
(mm {in})
0.06 {0.0024}
ROTOR
(mm {in})
(mm {in})
Apex seal groove and the apex seal clearance (mm {in})
Standard
0.05-0.19 {0.0020-0.0074}
0.12-0.18 {0.0048-0.0070}
Minimum
0.1 {0.0039}
Standard
0.042-0.101 {0.0017-0.0039}
(mm {in})
(mm {in})
Standard
5.3 {0.20}
Minimum
4.3 {0.17}
Standard
5.4 {0.213}
Minimum
3.5 {0.148}
(mm {in})
0.5 {0.02}
Standard
0.05-0.15 {0.0020-0.0059}
(mm {in})
0.5 {0.02}
Standard
3.95 {0.1555}
Minimum
3.8 {0.15}
(mm {in})
0.5 {0.02}
(mm {in})
0.5 {0.02}
(mm {in})
(mm {in})
0.5 {0.02}
Standard
0.055-0.075
{0.0022-0.0029}
(mm {in})
ECCENTRIC SHAFT
(mm {in})
0.045-0.085
{0.0018-0.0033}
(mm {in})
Runout
(mm {in})
End play
(mm {in})
Standard
0.06-0.08 {0.0024-0.0030}
0.02 {0.0008}
0.04-0.09 {0.0016-0.0035}
(mm {in})
6 {0.24}
OIL PUMP
Side clearance
Standard
(mm {in})
0.20-0.25 {0.0079-0.0098}
Tip clearance
(mm {in})
Body clearance
(mm {in})
Standard
0.03-0.12 {0.0012-0.0047}
0.03-0.125 {0.0012-0.0049}
ENGINE SST
BHE016001001E01
49 0107
680A
Engine
stand
49 1881
055A
Stopper
counter
weight (AT)
49 L010 1A0
49 J010 3A0A
Engine
hanger set
Hanger, Engine
stand
49 0820 035
49 0839 305A
Flywheel box
wrench
Counterweight
puller
49 F011 101
49 0813 250
Ring gear
brake
(MT)
49 0813
225A
Oil seal
remover
49 0839 165
Seal case
49 0813 235
Main bearing
puller and
installer
49 F011 1A1
49 0813 215A
Dowel puller and
oil pump puller
49 0813 240
Rotor bush puller
and installer
49 1285 071
Corner seal
gauge
Bearing
installer set
(MT)
Needle bearing
puller (MT)
49 G030
797
49 F010 401A
49 J027 001
Installer
Bearing installer
Handle (MT)
Warning
Continuous exposure to USED engine oil has caused skin cancer in laboratory mice. Protect your skin by
washing with soap and water immediately after this work.
ENGINE MOUNTING/DISMOUNTING
BHE011002000E02
Mounting
Using 49 L010 1A0
1. Remove the stud bolt.
2. Install the SSTs (arms) to the specified three position as
shown in the figure, and temporarily tighten with the SSTs
(bolts) and 99784 0890 or M81.25 length 90 mm {3.55
in} bolt.
3. Install the SSTs (bolt, nut) to the three specified positions as shown in the figure.
4. Install the SSTs (bolts, nuts, hook, plate) in Step 3 to
the SST (arms, bolts) set in Step 2.
5. Adjust the bolt threads by turning them so that they
project approx. 20 mm {0.79 in} from the plate end.
6. Adjust the bolts and nuts so that the plate and arms are
parallel.
7. Mount the engine to the SST (engine stand).
8. Remove the oil pan drain plug and drain the engine oil.
9. Replace with a new washer and install the oil pan drain plug.
Tightening torque
29.4-39.2 Nm {3.00-3.99 kgfm, 21.7-28.9 ftlbf}
Dismounting
1. Dismount in the reverse order of mounting.
2. Tighten the stud bolt. (Only when using 49 L010 101.)
Tightening torque
14.7-34.3 Nm {1.50-3.49 kgfm, 10.9-25.2 ftlbf}
HOUSING DISASSEMBLY I
BHE011002000E03
1. Disassemble in the order indicated in the table.
Thermostat component
Oil pan
(See Oil Pan Disassembly Note.)
Clip
10 Oil-level sensor
11 Oil strainer
HOUSING DISASSEMBLY II
BHE011002000E04
1. Disassemble in the order indicated in the table.
Pulley lockbolt
(See Pulley Lockbolt Disassembly Note.)
Pulley component
Spring
Front cover
(See Front Cover Disassembly Note.)
Plug
Control valve
Tension bolt
(See Tension Bolt Disassembly Note.)
Rear housing
(See Rear Housing Disassembly Note.)
Pressure regulator
Rear rotor
A: Side seal
B: Side seal spring
C: Corner seal
D: Corner seal plug
E: Corner Seal Spring
F: Side piece
G: Apex seal
H: Apex seal spring (short)
I: Apex seal spring (long)
(See Rotor Disassembly Note.)
10
11
Intermediate housing
(See Intermediate Housing Disassembly Note.)
12
13 Eccentric shaft
14 Oil jet plug
15 Spring
16 Steel ball
17
Front rotor
(See Rotor Disassembly Note.)
18 Plate
19 Needle bearing
20 Thrust plate
21
22 Front housing
Caution
If a seal adheres to the rear housing, put it back in
its original position in the rotor.
1. Remove the side piece, apex seal, corner seal, side seal, and spring on the engine rear side, and place them in
the SST while keeping them in order.
2. Move the rotor to the left and right to cut the oil film.
3. Remove the rotor.
Caution
If a seal adheres to the side housing, put it back in
its original position in the rotor.
Place the removed rotor upright on soft material
such as a rubber sheet or cloth. Do not allow the oil
seal to directly contact metal are similar hard
surface.
4. Remove the corner seal, side seal, and spring on the engine front side, and place them in the SST while keeping
them in order.
Caution
If a seal adheres to the intermediate housing, put
it back in its original position in the rotor.
ROTOR DISASSEMBLY
BHE011002000E06
1. Disassemble in the order indicated in the table.
1 Cut-off seal
2 Cut-off seal spring
3
Caution
ROTOR ASSEMBLY
BHE011002000E07
1. Assemble in the order indicated in the table.
Cut-off seal
(See Cut-Off Seal Assembly Note.)
Front rotor
Rear rotor
Rotor
Engine front side Engine rear side Engine front side
Inner
White
Blue
White
Blue
Blue + pink
White + pink
Blue + pink
Caution
It is possible that the identification color may not be visible when reusing the oil spring. In that case,
assemble the rounded end towards the rotor side and the squared end upward.
Be careful when assembling the oil seal spring of the front and rear rotor since each spring of the engine
front side and engine rear side are the same.
Note
Either one of the two rotation lock slots on the oil seal can be used as a reference.
Assemble the rounded end within 0-15 mm
{0-0.59 in} away from the oil seal spring
rotation lock.
Note
Note
When replacing a cut-off seal with a new one,
assemble the seal with the pink surface facing
upward.
HOUSING ASSEMBLY I
BHE011002000E08
1. Assemble in the order indicated in the table.
Front housing
Thrust plate
(See Thrust Plate Assembly Note.)
Needle bearing
Plate
Front rotor
A: Side seal
B: Side seal spring
C: Corner seal
D: Corner seal plug
E: Corner seal spring
F: Side piece
G: Apex seal
H: Apex seal spring (short)
I: Apex seal spring (long)
(See Rotor Assembly Note.)
Steel ball
Spring
10 Eccentric shaft
11
Intermediate housing
(See Intermediate Housing Assembly Note.)
14
Rear rotor
(See Rotor Assembly Note.)
15
20
Rear housing
(See Rear Housing Assembly Note.)
21
Tension bolt
(See Tension Bolt Assembly Note.)
22
2. Assemble the side seal spring in the direction shown in the figure.
3. Apply petroleum jelly between the side seal and side
seal groove.
4. Assemble the corner seal plug to the corner seal.
Note
When replacing a corner seal with new one,
assemble the corner seal with the painting surface
facing upward.
5. Assemble the corner seal and corner seal spring with the notch aligned with the apex seal groove.
6. Apply petroleum jelly between the corner seal and corner seal groove.
7. Insert the SST into the apex seal groove of the rotor and verify that the apex seal groove of the corner seal is
aligned with the apex seal groove of the rotor.
8. Assemble the side seal and corner seal for the engine rear side in the same way as the engine front side.
Caution
After adhesion, make sure that there is no gap
between the apex seal and side piece.
If adhesive protrudes, remove with a razor.
Note
When using a new apex seal, the procedure above is not needed.
6. Assemble the apex seal and apex seal spring (short) together with the side piece to the engine rear side.
7. Assemble the apex seal spring (long) while pressing the apex seal spring (short).
Caution
Assemble the apex seal spring until it catches the
spring stopper of the side piece.
Caution
Do not allow the side piece to be caught between
the rotor housing and intermediate housing.
Caution
Insert the rear oil seal until it is reaches to the
seating face.
Caution
Do not allow the side piece to be caught between the rotor housing and rear housing.
Caution
Assemble a tension bolt which has a seal washer
with the rubber projection facing the housing side.
2. Tighten the tension bolts in the order indicated in the
figure in 2-3 passes.
Tightening torque
31.4-39.2 Nm
{3.21-3.99 kgfm, 23.2-28.9 ftlbf}
HOUSING ASSEMBLY II
BHE011002000E09
1. Assemble in the order indicated in the table.
.
1
Shaft
Middle plate
Spacer
(See Spacer Assembly Note.)
Needle bearing
10 Thrust plate
11 Balance weight
12 Oil pump component
13
21
Front cover
(See Front Cover Assembly Note.)
22 Spring
23 Eccentric shaft bypass valve
24 Pulley component
25
Pulley lockbolt
(See Pulley Lockbolt Assembly Note.)
Oil strainer
Oil-level sensor
Clip
Oil pan
(See Oil Pan Assembly Note.)
Thermostat component
Apply the silicon sealant in a single, unbroken line around the whole perimeter.
Install the engine front cover within 5 min after applying the silicone sealant.
1. Completely clean and remove any oil, dirt, sealant or other foreign material that may be adhering to the housing
and oil pan.
2. When reusing oil pan installation bolts, clean any old sealant from the bolts.
3. Apply silicone sealant to the areas shown in the figure.
Bead thickness
2.5-6.5 mm {0.1-0.2 in}
4. Tighten the oil pan installation bolts.
Tightening torque
8.8-11.8 Nm
{90-120 kgfcm, 78-104 inlbf}
f
it
Caution
When assembling the spacer, do not allow the spacer to be caught in the needle bearing in the plate.
3. Assemble the eccentric shaft pulley, eccentric shaft
position plate, pulley boss component apply engine oil to
the pulley lockbolt threads, and then tighten.
Tightening torque
300-340 Nm {30.6-34.6 kgfm, 222-250 ftlbf}
4. Remove the SST.
5. Measure the end play of the eccentric shaft using a dial
gauge.
If not within the specification, replace the spacer with one that is thicker than the currently assembled one.
If it exceeds the specification, replace with a thinner spacer.
Standard end play
0.04-0.09 mm {0.0016-0.0035 in}
Maximum end play
Dimension
7.985 {0.3144}
8.005 {0.3152}
8.025 {0.3159}
8.045 {0.3167}
8.065 {0.3175}
Note
If the end play is not within the specification even after replacing with an A-marked spacer, adjust by
grinding it and reuse.
Inspection
Caution
Inspect the pilot bearing when it is installed to the eccentric shaft.
1. Before removing the pilot bearing, inspect it for damage, wear, and proper rotation.
Replacement
Removal
1. Fix the eccentric shaft on a vice.
2. Remove the pilot bearing and the oil seal together using the SST.
Installation
1. Install a new pilot bearing using the SSTs.
Warning
Engine oil temperature will increase during the inspection and become very dangerous. Be careful not to
burn yourself during the inspection.
1. Put the eccentric shaft bypass valve in a container filled with engine oil.
2. Heat the container and verify that the projection
protrudes more than the minimum specification when the
engine oil temperature is 60 C {140 F}.
Caution
Carefully inspect the anti-wet port of the
intermediate housing since it is an essential
port.
Maximum wear
0.10 mm {0.0039 in}
(2) Convex oval
Maximum wear
Oil seal inner path (A): 0.01 mm {0.0004 in}
Oil seal outer path (B): 0.10 mm {0.0039 in}
(3) Oil seal stepped path wear
Maximum wear
0.02 mm {0.0008 in}
3. Calculate the main bearing oil clearance from the main journal outer diameter and the main bearing inner
diameter.
Main bearing oil clearance = (main bearing inner
diameter) - (main journal outer diameter)
Removal
1. Remove the stopper screw. (High power only)
2. Remove the adapter ring and the securing screw from
the SST.
3. Set the stationary gear to the hydraulic press so that the
gear faces upward.
4. Remove the main bearing using the SST.
Installation
Standard power
1. Temporally assemble the stationary gear and the main bearing so that the main bearing tab and notch are
aligned after pressing in the main bearing and stationary gear.
2. Remove the SST handle.
3. Position the gear of the stationary gear downward, and
install the main bearing by pressing it with the SST.
Caution
Press the main bearing in so that the top of the
main bearing is flush with the top of the stationary
gear flange.
High power
1. Temporarily assemble the stationary gear and the main
bearing so that the main bearing screw hole and the
stationary gear screw hole are aligned after pressing in the main bearing and rotor.
2. Remove the SST handle.
3. Position the gear of the stationary gear downward, and install the main bearing using the SST.
Caution
Press the main bearing in so that the top of the
main bearing is flush with the top of the stationary
gear flange.
4. Apply thread-locking compound to the stopper screw
and install.
Tightening torque
3.2-4.7 Nm
{33-47 kgfcm, 29-41 inlbf}
ROTOR INSPECTION
BHE011011B10E01
1. Inspect the rotor and side housing clearance according to the following procedure:
Caution
Move the sheet metal piece out of the way when measuring.
(2) Measure the rotor width at various positions around the rotor round periphery using a micrometer.
(3) Compute the rotor and side housing clearance using the measurements from (1) and (2).
Rotor and side housing clearance = (rotor housing width) - (maximum rotor width)
Standard clearance
0.05-0.19 mm {0.0020-0.0074 in}
Minimum clearance
0.05 mm {0.002 in}
2. Measure the protrusion of the rotor round using a straight edge and a feeler gauge.
Caution
Measure the the protrusion of the rotor round in the three apexes of the rotor on both the front and rear
sides.
Because the rotor round has two levels, be careful not to measure the level difference of the middle level.
If 1/2 or more of either end of the SST can be inserted into the seal groove, replace the corner seal.
If 1/2 or more of both ends of the SST can be inserted into the corner seal groove, replace the rotor.
Caution
Do not push the SST in with force.
Keep the SST perpendicular to the seal groove.
When replacing the corner seal, replace with one that matches the S or L inscription on the rotor.
4. Measure the clearance between the apex seal groove and the apex seal using a feeler gauge.
Caution
Press the feeler gauges against the both ends of
the side seals correctly.
Note
Any side seal height is acceptable.
3. Measure the clearance between both ends of the side
seal and the corner seal using a feeler gauge.
N3Z1 11 C10*
H
I
J
K
L
N3Z2 11 C10*
M
N
O
P
N3Z3 11 C10*
Q
R
S
T
N3Z4 11 C10*
U
* : Revision indication (alphabetical order)
Caution
Measure the cut-off seal height around the
complete perimeter.
Standard height
3.95 mm {0.1555 in}
Minimum height
3.8 mm {0.15 in}
If either of the items exceeds the maximum specification, replace the oil seal.
(1) Width of area that contacts the oil seal lip.
Caution
Measure the contact width around the complete perimeter.
Maximum contact width
0.5 mm {0.02 in}
(2) Circumferential width of any damage along the lip.
SPRING INSPECTION
BHE011011B10E06
Caution
Measure the rotor journal at a point slightly offcenter since the center section is raised. Do not
measure at the center because it does not
contact the rotor bearing.
2. Measure the inner diameter of the rotor bearing using
a cylinder gauge.
3. Calculate the rotor bearing oil clearance from the rotor journal outer diameter and the rotor bearing inner
diameter.
Rotor bearing oil clearance = (rotor bearing
inner diameter) - (rotor journal outer diameter)
Removal
1. Set the rotor with the internal gear at the bottom.
2. Remove the adapter ring and the securing screw from the SST.
3. Remove the rotor bearing using the SST.
Installation
1. Remove the SST handle.
2. Temporarily assemble so that the rotor bearing tab and the rotor notch are aligned after pressing in the rotor
bearing and rotor.
3. Set the temporarily assembled rotor bearing and rotor
on a hydraulic press.
4. Press in the rotor bearing using the SST.